Electro-Hydraulic Control Design for Pump Discharge Pressure Control
An electro-hydraulic control system manages speed of a hydraulic fan by using a solenoid to bias a three position pool of a control valve coupled to a hydraulic pump driving the fan. In a first position, the spool releases pressure on a de-stroke actuator of the pump and allows an on-stroke actuator to increase output pressure corresponding to a speed of an engine driving the pump. In a second position, the spool isolates the de-stroke actuator and fixes the pressure output of the pump. In a third position, the spool couples the de-stroke actuator to the pump output and causes a reduction in the pressure output of the pump. The solenoid coupled to the spool sets the output pressure at which the spool is in the second position.
Latest CAPTERPILLAR, INC. Patents:
The present disclosure generally relates to hydraulics, and more particularly relates to hydraulically operated piston pumps.
BACKGROUNDHydraulic fluid is used in a variety of machines to produce useful work. In order to provide the hydraulic fluid to drive cylinders or motors, one or more hydraulic pumps are typically provided on a machine and are driven by the engine of the machine. Such pumps can be provided in a number of different forms, with axial piston pumps being one common example. With an axial hydraulic piston pump, a central barrel or block is rotatedly driven by the motor. The barrel includes a plurality of cylinders each of which is adapted to receive a reciprocating piston. At a driven end, each of the pistons is pivotally and slidably engaged with a swashplate angularly positioned relative to the cylinder barrel. At a work end of each cylinder, a valve plate is provided having two or more inlets and outlets. During the inlet phase of operation, hydraulic fluid is drawn in through the inlet of the valve plate, and into the cylinders of the rotating barrel. This drawing in or filling of the cylinders occurs as the barrel rotates, and the pistons of the barrel proximate to the inlet move from a top dead center position to bottom dead center position. The rotation of the barrel and size of the inlets are such that once the piston reaches its bottom dead center position, the cylinders rotate out of communication with the inlet of the valve plate. Further rotation of the barrel causes the cylinders, now completely filled with hydraulic fluid, to create fluid flow as the pistons move from the bottom dead center position to the top dead center position. During travel from the bottom dead center to the top dead center position, the cylinders are placed into communication with the outlet of the valve plate such that the hydraulic fluid can be delivered from the pump to provide for useful work such as the aforementioned driving of implements, work arms, motors, etc.
Many applications require hydraulic pump pressure control. For example, a hydraulic fan drive system may require variable speed up to a maximum speed, beyond which no further speed increase is either needed or desirable. Ideally, the maximum speed should be settable so that it can be adjusted based on environmental or other conditions.
In applications using hydraulic fan drive speed control, there are two main architectures, a first architecture, a pump pressure control using a load sensing pump with an electro-hydro-mechanical pressure control circuit for generating the load sensing signal and, a second architecture, a displacement controlled pump. In the former architecture, represented by U.S. Patent Application 2004/0261407 to the same inventor as the current disclosure, the margin pressure across the control load sensing control valve will regulate the pump discharge pressure around the load sensing pressure plus margin pressure. In addition to the outer electronic control loop, this control design involves two hydro-mechanical loops, a pressure control loop for load sensing pressure and a pressure control loop for pump discharge pressure. The three control loops can result in some system instability. The electro-hydro-mechanical pressure control circuit can increase the cost and reduce the control system reliability. Further, there is no particular failure mode such that a failure in the control electronics may leave the system in an unknown state.
In the latter system, that uses a displacement controlled pump, the fan speed is directly controlled by the pump flow regardless of the pump discharge pressure. Due to the insensitivity to the fan drive torque (the pump discharge pressure), the displacement controlled pump can put a high load on the engine unnecessarily. Also, because of the large inertia of the fan drive system, the displacement controlled pump can be exposed to low pump discharge pressures that could result in damage to the pump and/or the other components in the related hydraulic system.
SUMMARY OF THE DISCLOSUREIn one example of the present invention, a hydraulic fan system is provided. The system may include a hydraulic pump configured for variable displacement operation and may include a swashplate that controls a displacement of the hydraulic pump, a discharge signal passage of the pump, an on-stroke actuator coupled to the swashplate that, when advanced, increases an angle of the swashplate to increase a pressure at the discharge signal passage. The on-stroke actuator may also be coupled to the discharge signal passage. The system may also include a de-stroke actuator coupled to the swashplate that, when advanced, decreases an angle of the swashplate to decrease the pressure at the discharge signal passage and a control valve coupled to the on-stroke actuator, the de-stroke actuator of the hydraulic pump, and a tank. The control valve may include a spool responsive to pressure changes at the discharge signal passage and is operable: i) in a first position, to connect the de-stroke actuator to the tank, ii) in a second position, to isolate the de-stroke actuator from both the discharge signal passage and the tank, and iii) in a third position, to connect the de-stroke actuator to the discharge signal passage. The spool may be adapted to respond to increases in pressure in the discharge signal passage by moving consecutively from the first position to the second position to the third position. The control valve may also include a spring that biases the spool toward the first position and a solenoid disposed opposite the spring that provides a settable force that biases the spool toward the third position. Lastly, the system may include a hydraulic motor driving a fan blade, the hydraulic motor coupled to the hydraulic pump and having a speed corresponding to a pressure at the discharge signal passage of the hydraulic pump.
In another embodiment, a pressure control system for use with a variable displacement hydraulic pump may have a swashplate with a swashplate angle controlled by opposing stroke actuators, and may include a control valve hydraulically coupled to a de-stroke actuator, a discharge signal passage of the pump, and a tank, where the discharge signal passage also connected to an on-stroke actuator, a spool of the control valve controllably operable: i) in a first position, to connect the de-stroke actuator to the tank, ii) in a second position, to isolate the de-stroke actuator from both the discharge signal passage and the tank, and iii) in a third position, to connect the de-stroke actuator to the discharge signal passage, the spool adapted to respond to increases in pressure in the discharge signal passage by moving consecutively from the first position to the second position to the third position. The pressure control system may also include a spring that biases the spool toward the first position, and a solenoid disposed opposite the spring that provides a force that biases the spool toward the third position.
In yet another embodiment, a method of operating a hydraulic fan may include, in a first operating mode, providing variable cooling via a hydraulic fan operated at a rate in a direct proportion to a speed of an engine up to a threshold speed of the engine and in a second operating mode, providing constant cooling via the hydraulic fan operated at a fixed rate for any engine speed above the threshold speed of the engine. The method may also include adjusting a solenoid force applied to a hydraulic control valve to set the threshold speed of the engine.
Generally, a hydraulic fan system uses a hydraulic motor to drive an associated fan. In this environment, hydraulic fan control may be modeled as a function of motor torque and fan torque in view of a discharge pressure of a drive pump. The torque losses on a fan mainly come from friction torque loss and its windage torque loss, where friction torque includes Coulomb friction torque and viscous friction torque. The friction torque can be expressed as:
Tf=ccfPp+cvdωF (1)
where ccf is the constant of Coulomb friction and cvd is the viscous damping coefficient, ωF is the fan speed, and Pp is the pump discharge pressure. It should be noted that the friction torque is related to the pump discharge pressure and the fan speed. The windage torque will be in the form of:
Tw=cwdωF2 (2)
where cwd is a constant determined by the structure and the geometric parameters of the fan. The drive torque for the fan comes from the hydraulic motor and it can be calculated by:
Tm=PpDmηt,m (3)
where ηt,m is the torque efficiency of the motor. Let JF denote the momentum of the inertia for the fan and the motor, so that the dynamic equation for the fan, using Newton's law, is:
PpDmηt,m−ccfPp−cvdωF−cwdωF2=JF{dot over (ω)}p, (4)
Rearranging Eq. (4):
JF{dot over (ω)}F+cvdωF+cwdωF2=(Dmηt,m−ccf)Pp (5)
For steady state, {dot over (ω)}p=0, the torque balance is:
cvdωF+cwdωF2=(Dmηt,m−ccf)Pp (6)
Eq. (6) indicates that the fan speed can be controlled solely by the pump discharge pressure Pp. Therefore, the control of fan speed can be reduced simply to that of controlling pump discharge pressure.
Eq. (5), above, reveals that the pump discharge pressure is dynamically related to the fan speed and physically the two variables will reach the equilibrium expressed by Eq. (6). In other word, equations (5) and (6) show that control of the fan speed can be implemented by controlling the pump discharge pressure. Based on this,
Referring to
Fsppi+Ksprgxv=Fs+ΔAsiPp (7)
where Fsppi is the pre-load force on the spring, Ksprg is the spring rate of the balance spring, Fs is the solenoid force, xv is the spool metering land position, and ΔAsi is the area difference between the metering land 50 and the pressure feedback land 52. The origin (or first position) of the spool is when the spool touches the very left end (the solenoid side), as shown in
Fsppi+ksprg+xv,0=Fs,max+ΔAsiPp,min (8)
On the other hand, with zero as the minimum solenoid force for the constant fan speed, or Fs,min=0, we have
Fsppi+ksprgxv,0=ΔAsiPp,min (9)
By Eqs. (8) and (9), the differential area can be calculated by
ΔAsi=Fs,max Pp,max−Pp,min (10)
Given the spool differential area, the control valve can be designed to meet the requirements for given application with the appropriate areas for the metering land 50 and the pressure feedback land 52.
In an exemplary embodiment, the pressure control system 22 may also include a pump discharge line or passage 27, a control line 28, a hydraulic pump 30 including a variable pitch swashplate 31, an on-stroke actuator 32, an on-stroke bias spring 33, a de-stroke actuator 34, the pump control actuator chamber 35, and an on-stroke hard stop 36 that limits the maximum angle of the swashplate and therefore the maximum pressure output of the pump 30. The pressure control system 22 may also include pressure equalizing passages 38 and 39 that surround lands 52 and 56, respectively. A cutoff land 54 may divert pressure to the pump control actuator chamber 35, as described further below. Other embodiments of the pressure control system 22 may be contemplated beyond the illustrated exemplary embodiment, such as different configurations of spool 24, actuators 32, 34, etc., without affecting the functions performed to achieve pump pressure control.
In operation, the pressure control system 22 may begin operation as illustrated in
Referring to
Correspondingly, when the engine speed is reduced, the output pressure drops and the spool 24 will move to the first position illustrated in
While this negative feedback system is useful as described, an additional level of flexibility is available via the further ability to set the knee (e.g., point A of
Therefore, the threshold engine speed at which the pressure control system 22 changes from a first operating mode of variable pump pressure and fan speed to a second operating mode with constant pump pressure and fan speed independent of engine speed, may be controlled electrically by adjusting the current through the solenoid. This allows a variety of factors affecting operation of the overall machine to influence, in this embodiment, fan speed and cooling capacity. Fan speed and, ultimately, cooling capacity is therefore settable based on observed or measured factors. For example, an extremely cold environment may have a reduced cooling requirement so that engine power may be diverted from the fan and applied to other areas of the machine. Or, in another example, extreme loads on the machine may increase the cooling requirement, requiring a higher maximum fan speed.
At a block 64, a solenoid current is established that sets a force to bias a spool of a pressure control valve. At a block 66, in a first operating mode, the hydraulic fan 17 is operated to provide variable cooling at a rate in a direct proportion to a speed of the engine 11 up to a threshold speed of the engine 11. In the first operating mode, a spool 24 of the control valve 23 is set to a first position that connects a de-stroke actuator 34 of the hydraulic pump to a low pressure tank 29. Further, the spool 24 at the first position permits pressure applied to an on-stroke actuator to increase the angle of a swashplate causing an increase in output pressure of the hydraulic pump. Therefore, a change in engine speed affects speed of the pump 30 and causes a proportional change in the output pressure of the pump 30. Because the hydraulic fan speed is a direct function of pump pressure, the cooling provided by the fan is proportional to the engine speed, when operating in the first mode.
Adjusting the solenoid force applied to the control valve to zero sets the threshold speed of the engine to a maximum engine speed. That is, setting the solenoid force to zero, or a failure of the solenoid (25) or its drive circuit, will remove any limit on maximum pressure and allow a failsafe mode of maximum pressure and in an exemplary embodiment, maximum fan speed.
At a block 68, pressure change at the pump 30 is measured in accordance with equation (7) above. When the output pressure of the pump is at the set level, the ‘Yes’ branch may be taken from the block 68 to a block 70. At the block 70, in a second operating mode, a spool 24 of the control valve 23 is set to a second position that isolates a de-stroke actuator 34 of the hydraulic pump 30 and fixes an angle of a swashplate to provide a constant pressure output of the hydraulic pump 30. Constant cooling is provided via the hydraulic fan 17 operated at a fixed rate for a given engine speed above the threshold speed setting.
Returning to the block 68, if a pressure increase at the output of the pump is detected, for example, if the engine speed increases, the ‘Too high’ branch from block 68 may be taken to block 72. While still operating in the second operating mode, the spool 24 of the control valve 23 may be set to a third position that connects the de-stroke actuator 34 of the hydraulic pump 30 to a discharge signal passage 27, or output, of the hydraulic pump causing the de-stroke actuator 34 to decrease an angle of a swashplate 31 to reduce an output pressure of the hydraulic pump 30. The cooling provided by the fan will remain virtually constant as the spool 24 is returned to the null position (see
The configuration described may also be used in applications requiring failsafe operation at maximum output pressure or maximum speed. As can be seen, if the power to the solenoid is interrupted, a properly sized differential land area between lands 50 and 52 will drive the spool 24 to the first position and allow the pump 30 to operate at full displacement for any engine speed.
INDUSTRIAL APPLICABILITYIn general, the present disclosure describes a hydraulic pump pressure control system that uses an electro-hydraulic control to variably set a maximum pump output pressure. A variety of hydraulically operated equipment may benefit from the ability to use the hydraulic negative feedback and settable maximum pressure provided by this system and method. In the exemplary embodiment, the fan control system provides the ability to tailor the cooling provided to match the system needs, based on factors including ambient temperature, heat generated, fan noise, fan power, etc. This capability is particularly applicable to heavy machinery, such as earthmoving equipment, tractors, loaders, etc.
The hydraulic pump pressure control system eliminates the multiple pressure sensing control loops of the prior art system resulting in a more stable system.
In other embodiments, any hydraulically operated mechanism requiring a settable constant maximum pressure may benefit from the above-described system and method, especially when pump speed is subject to wide variations.
In still other embodiments, any system requiring a failsafe mode of maximum pressure or maximum speed may use this system and method. Should there be a failure in the solenoid or the electrical system operating the solenoid, the pressure control system will operate in the first mode with the swashplate kept at the maximum angle to provide a maximum available pressure at the pump output and correspondingly, maximum speed to an implement such as a fan.
Claims
1. A method of operating a hydraulic fan comprising:
- in a first operating mode, providing variable cooling via a hydraulic fan operated at a rate in a direct proportion to a speed of an engine up to a threshold speed of the engine;
- in a second operating mode, providing constant cooling via the hydraulic fan operated at a fixed rate for any engine speed above the threshold speed of the engine; and
- adjusting a solenoid force applied to a hydraulic control valve coupled to the engine and the hydraulic fan to set the threshold speed of the engine.
2. The method of claim 1, further comprising:
- driving a hydraulic pump with the engine, the hydraulic pump having a variable displacement output settable by an angle of a swashplate.
3. The method of claim 1, further comprising:
- in the first operating mode, setting a spool of the control valve to a first position that connects a de-stroke actuator of the hydraulic pump to a low pressure tank and permits pressure applied to an on-stroke actuator to increase the angle of a swashplate causing an increase in output pressure of the hydraulic pump.
4. The method of claim 1, further comprising:
- in the second operating mode, setting a spool of the control valve to a second position that isolates a de-stroke actuator of the hydraulic pump and fixes an angle of a swashplate to provide a constant pressure output of the hydraulic pump.
5. The method of claim 1, further comprising:
- in the second operating mode, setting a spool of the control valve to a third position that connects a de-stroke actuator of the hydraulic pump to an output of the hydraulic pump causing the de-stroke actuator to decrease an angle of a swashplate to reduce an output pressure of the hydraulic pump.
6. The method of claim 1, wherein adjusting the solenoid force applied to the hydraulic control valve comprises adjusting the solenoid force applied to the control valve to zero sets the threshold speed of the engine to a maximum engine speed.
7. A hydraulic fan system comprising:
- a hydraulic pump configured for variable displacement operation including: a swashplate that controls a displacement of the hydraulic pump; a discharge signal passage; an on-stroke actuator coupled to the swashplate that, when advanced, increases an angle of the swashplate to increase a pressure at the discharge signal passage, the on-stroke actuator further coupled to the discharge signal passage; a de-stroke actuator coupled to the swashplate that, when advanced, decreases an angle of the swashplate to decrease the pressure at the discharge signal passage; and
- a control valve coupled to the on-stroke actuator, the de-stroke actuator of the hydraulic pump, and a tank, the control valve including: a spool responsive to pressure changes at the discharge signal passage and operable: i) in a first position, to connect the de-stroke actuator to the tank, ii) in a second position, to isolate the de-stroke actuator from both the discharge signal passage and the tank, and iii) in a third position, to connect the de-stroke actuator to the discharge signal passage, the spool adapted to respond to increases in pressure in the discharge signal passage by moving consecutively from the first position to the second position to the third position; a spring that biases the spool toward the first position; and a solenoid disposed opposite the spring that provides a settable force that biases the spool toward the third position; and
- a hydraulic motor driving a fan blade, the hydraulic motor coupled to the hydraulic pump and having a speed corresponding to a pressure at the discharge signal passage of the hydraulic pump.
8. The hydraulic fan system of claim 7, wherein the on-stroke actuator includes a bias spring to place the hydraulic pump in a maximum displacement state absent pressure at the discharge signal passage.
9. The hydraulic fan system of claim 7, wherein a land area of the de-stroke actuator is larger than a land area of the on-stroke actuator such that exposure of both actuators to pressure from the discharge signal passage causes the swashplate to de-stroke the hydraulic pump.
10. The hydraulic fan system of claim 9, wherein the land area of the de-stroke actuator is sufficiently larger than the land area of the on-stroke actuator to overcome the force of the bias spring and the on-stroke actuator when both actuators are exposed to pressure from the discharge signal passage.
11. The hydraulic fan system of claim 7, wherein the spool has a spool lands differential area between a first spool land and a second spool land that results in spool movement in a direction from the first position toward the third position responsive to increases in pressure in the discharge signal passage.
12. The hydraulic fan system of claim 7, further comprising a hard stop that limits a maximum on-stroke angle of the swashplate.
13. The hydraulic fan system of claim 7, wherein the settable force of the solenoid is set to a force corresponding to a maximum desired hydraulic pump output pressure.
14. A pressure control system for use with a variable displacement hydraulic pump having a swashplate with a swashplate angle controlled by opposing stroke actuators, the pressure control system comprising:
- a control valve hydraulically coupled to a de-stroke actuator, a discharge signal passage of the pump, and a tank, the discharge signal passage also connected to an on-stroke actuator;
- a spool of the control valve controllably operable: i) in a first position, to connect the de-stroke actuator to the tank, ii) in a second position, to isolate the de-stroke actuator from both the discharge signal passage and the tank, and iii) in a third position, to connect the de-stroke actuator to the discharge signal passage, the spool adapted to respond to increases in pressure in the discharge signal passage by moving consecutively from the first position to the second position to the third position;
- a spring that biases the spool toward the first position; and
- a solenoid disposed opposite the spring that provides a force that biases the spool toward the third position.
15. The pressure control system of claim 14, wherein the force of the solenoid is controllable.
16. The pressure control system of claim 15, wherein the force of the solenoid corresponds to a maximum desired hydraulic pump output pressure.
17. The pressure control system of claim 14, wherein the spool has a spool lands differential area between a first spool land and a second spool land that results in spool movement in a direction from the first position toward the third position responsive to increases in pressure in the discharge signal passage.
18. The pressure control system of claim 14, wherein a decrease in pressure in the discharge signal passage allows the spring to move the spool toward the first position.
19. The pressure control system of claim 18, wherein a pressure in the discharge signal passage that causes the spring to move the spool toward the first position is determined by the settable force supplied by the solenoid.
20. The pressure control system of claim 14, wherein in a failure of the solenoid causing a loss of force that biases the spool toward the third position allows the spool to travel to the first position and causes the pump to output a maximum pressure.
Type: Application
Filed: Aug 30, 2012
Publication Date: Mar 6, 2014
Applicant: CAPTERPILLAR, INC. (Peoria, IL)
Inventor: Hongliu Du (Naperville, IL)
Application Number: 13/599,794
International Classification: F16D 31/02 (20060101);